tank TOYOTA HIGHLANDER 2001 Service Repair Manual

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Always slow down in gusty cross-
winds. Because of its profile and
higher center of gravity, your ve-
hicle is more sensitive to side
winds than an ordinary passenger
car. Slowing down will allow you to
have better control.

When driving off- road or in rugged
terrain, do not drive at excessive
speeds, jump, make sharp turns,
strike objects, etc. This may cause
loss of control or vehicle rollover
causing death or serious injury. You
are also risking expensive damage
to your vehicle's suspension and
chassis.

Do not drive horizontally across
steep slopes. Driving straight up or
straight down is preferred. Your ve-
hicle (or any similar off- road ve-
hicle) can tip over sideways much
more easily than forward or back-
ward.
Drive gently and avoid high speeds.
Your vehicle does not need an elaborate
break- in. But following a few simple tips
for the first 1600 km (1000 miles) can add
to the future economy and long life of
your vehicle:

Avoid full throttle acceleration when
starting and driving.

Avoid racing the engine.

Try to avoid hard stops during the first
300 km (200 miles).

Do not drive for a long time at any
single speed, either fast or slow.

Do not tow a trailer during the first 800
km (500 miles).FUEL TYPE
Your new vehicle must use only un-
leaded gasoline.
To help prevent gas station mix- ups, your
Toyota has a smaller fuel tank opening.
The special nozzle on pumps with un-
leaded fuel will fit it, but the larger stan-
dard nozzle on pumps with leaded gas will
not.
At a minimum, the gasoline you use
should meet the specifications of ASTM
D4814 in the U.S.A. and CGSB 3.5- M93
in Canada.NOTICE
Do not use leaded gasoline. Use of
leaded gasoline will cause the three-
way catalytic converter to lose its ef-
fectiveness and the emission control
system to function improperly. Also,
this can increase maintenance costs.
Break- in period Fuel

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GASOLINE CONTAINING MMT
Some gasoline contain an octane en-
hancing additive called MMT (Methylcy-
clopentadienyl Manganese Tricarbonyl).
Toyota does not recommend the use of
gasoline that contains MMT. If fuel con-
taining MMT is used, your emission con-
trol system may be adversely affected.
The Malfunction Indicator Lamp on the in-
strument cluster may come on. If this hap-
pens, contact your Toyota dealer for ser-
vice.
GASOLINE QUALITY
In a very few cases, you may experience
driveability problems caused by the partic-
ular gasoline that you are using. If you
continue to have unacceptable driveability,
try changing gasoline brands. If this does
not rectify your problem, then consult your
Toyota dealer.NOTICE

Do not use gasohol other than
stated above. It will cause fuel sys-
tem damage or vehicle performance
problems.

If driveability problems occur (poor
hot starting, vaporizing, engine
knock, etc.), discontinue the use.

Take care not to spill gasohol dur-
ing refueling. Gasohol may cause
paint damage.
FUEL TANK CAPACITY
72.5 L (19.1 gal., 16.0 Imp. gal.)The fuel pump shut off system stops sup-
plying fuel to the engine to minimize the
risk of fuel leakage when the engine stalls
or an airbag inflates upon collision. To
restart the engine after the fuel pump shut
off system activates, turn the ignition
switch to ACCº or LOCKº once and start
it.
CAUTION
Inspect the ground under the vehicle
before restarting the engine. If you
find that liquid has leaked onto the
ground, it is the fuel system has
been damaged and it is in need of
repair. In this case, do not restart the
engine.
Fuel pump shut off system

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Check the interior of your vehicle. Wa-
ter and dirt can accumulate under the
floor mats and could cause corrosion. Oc-
casionally check under the mats to make
sure the area is dry. Be particularly care-
ful when transporting chemicals, cleans-
ers, fertilizers, salt, etc.; these should be
transported in proper containers. If a spill
or leak should occur, immediately clean
and dry the area.
Use mud shields on your wheels. If you
drive on salted or gravel roads, mud
shields help protect your vehicle. Full- size
shields, which come as near to the ground
as possible, are the best. We recommend
that the fittings and the area where the
shields are installed be treated to resist
corrosion. Your Toyota dealer will be
happy to assist in supplying and installing
the shields if they are recommended for
your area.
Keep your vehicle in a well ventilated
garage or a roofed place. Do not park
your vehicle in a damp, poorly venti-
lated garage. If you wash your vehicle in
the garage, or if you drive it covered with
water or snow, your garage may be so
damp as to cause corrosion. Even if your
garage is heated, a wet vehicle can cor-
rode if the ventilation is poor.Washing your Toyota
Keep your vehicle clean by regular
washing.
The following cases may cause weakness
to the paint or corrosion to the body and
parts. Wash your vehicle as soon as pos-
sible.

When driving in a coastal area

When driving on a road sprinkled with
antifreeze

When exposed to coal tar, tree sap,
bird droppings and carcass of an insect

When driving in areas where there is
a lot of smoke, soot, dust, iron dust or
chemical substances

When the vehicle becomes remarkably
dirty with dust and mud
Hand- washing your Toyota
Work in the shade and wait until the
vehicle body is not hot to the touch.
CAUTION
When cleaning under floor or chassis,
be careful not to injure your hands.
1. Rinse off loose dirt with a hose. Re-
move any mud or road salt from the
underside of the vehicle or in the
wheel wells.
2. Wash with a mild car- wash soap,
mixed according to the manufacturer 's
instructions. Use a soft cotton mitt and
keep it wet by dipping it frequently into
the wash water. Do not rub hardÐlet
the soap and water remove the dirt.
Fuel filler door: Do not apply water (high-
pressure car wash, for example) at or
near the fuel tank inlet with the fuel filler
door opened. If the water enters the air
vent, you may experience trouble with re-
fueling or rough engine idling.
Plastic wheel ornaments: The plastic
wheel ornaments are damaged easily by
organic substances. If any organic sub-
stances splashes an ornament, be sure to
wash it off with water and check if the
ornament is damaged.
CAUTION
Do not attach the heavily damaged
plastic wheel ornament. It may fly off
the wheel and cause accidents while
the vehicle is moving.
Washing and waxing your
To y o t a

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If you are a skilled do- it- yourself mechan-
ic, the Toyota service manuals are recom-
mended. Please be aware that do- it- your-
self maintenance can affect your warranty
coverage. See Owner 's Warranty Informa-
tion Bookletº or Owner 's Manual Supple-
mentº for the details.Listed below are the general maintenance
items that should be performed as fre-
quently as specified. In addition to check-
ing the items listed, if you notice any
unusual noise, smell or vibration, you
should investigate the cause or take your
vehicle to your Toyota dealer or a quali-
fied service shop immediately. It is recom-
mended that any problem you notice be
brought to the attention of your dealer or
the qualified service shop for their advice.
CAUTION
Make these checks only with ade-
quate ventilation if you run the en-
gine.
IN THE ENGINE COMPARTMENT
Items listed below should be checked
from time to time, e.g. each time when
refueling.
Washer fluid
Make sure there is sufficient fluid in the
tank. See page 399 in Section 7- 3 for
additional information.Engine coolant level
Make sure the coolant level is between
the Fº and Lº lines on the see- through
reservoir when the engine is cold. See
page 383 in Section 7- 2 for additional
information.
Radiator, condenser and hoses
Check that the front of the radiator and
condenser are clean and not blocked with
leaves, dirt or insects. See page 384 in
Section 7- 2 for additional information.
Battery electrolyte level
Your Toyota has a maintenance free bat-
tery. You do not have to add distilled wa-
ter. For longer life of the battery, however,
see page 396 for additional information.
Brake fluid level
Make sure the brake fluid level is correct.
See page 384 in Section 7- 2 for addition-
al information.
Engine oil level
Check the level on the dipstick with the
engine turned off and the vehicle parked
on a level spot. See page 380 in Section
7- 2 for additional information.
General maintenance

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Some states have vehicle emission in-
spection programs which include OBD
(On- Board Diagnostics) checks.
The OBD system monitors the operation
of the emission control system. When the
OBD system determines that a problem
exists somewhere in the emission control
system, the malfunction indicator lamp
comes on. In this case, your vehicle may
not pass the I/M test and need to be
repaired. Contact your Toyota dealer to
service the vehicle.
Even if the malfunction indicator lamp
does not come on, your vehicle may not
pass the I/M test as readiness codes
have not been set in the OBD system.
Readiness codes are automatically set
during ordinary driving. However, when the
battery is disconnected or run down, the
codes are erased. Also, depending on
your driving habits, the codes may not be
completely set.
Also, if the malfunction indicator lamp had
come on recently due to temporary mal-
function such as a loose fuel tank cap,
your vehicle may not pass the I/M test.The malfunction indicator lamp will go off
after taking several driving trips, but the
error code in the OBD system will not be
cleared unless about 40 trips or more are
taken.
If your vehicle does not pass the I/M test
even the malfunction indicator lamp does
not come on, contact your Toyota dealer
to prepare the vehicle for re- testing.
Emissions Inspection and
Maintenance (I/M) programs

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Fuel type:
2AZ- FE engine
Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or
higher
3MZ- FE engine
Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or
higher. For improved vehicle perfor-
mance, the use of premium unleaded
gasoline with an Octane Rating of 91
(Research Octane Number 96) or
higher is recommended.
Fuel tank capacity, L (gal., Imp. gal.):
72.5 (19.1, 16.0)ENGINE
Valve clearance (engine cold), mm (in.):
2AZ- FE engine
Intake 0.19Ð0.29 (0.007Ð0.011)
Exhaust 0.30Ð0.40 (0.012Ð0.016)
3MZ- FE engine
Intake 0.15Ð0.25 (0.006Ð0.010)
Exhaust 0.25Ð0.35 (0.010Ð0.014)
Spark plug type:
DENSO SK20R11
NGK IFR6A11
Spark plug gap, mm(in.):
1.1 (0.043)
Drive belt tension measured with
Borroughs drive belt tension gauge
No.BT- 33- 73F (used belt), Ibf:
2AZ- FE engine
Automatic adjustment
3MZ- FE engine
12510ENGINE LUBRICATION
Oil capacity (drain and refill), L (qt., Imp.
qt.):
2AZ- FE engine
With filter 3.8 (4.0, 3.3)
Without filter 3.6 (3.8, 3.2)
3MZ- FE engine
With filter 4.7 (5.0, 4.1)
Without filter 4.5 (4.8, 4.0)
Toyota Genuine Motor Oilº is used in
your Toyota vehicle. Use Toyota approved
Toyota Genuine Motor Oilº or equivalent
to satisfy the following grade and
viscosity.
Oil grade:
API grade SL Energy- Conservingº or
ILSAC multigrade engine oil
Fuel Service specifications

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OPERATION OF INSTRUMENTS AND
CONTROLS
Keys and Doors
Keys14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine immobilizer system17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wireless remote control18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side doors24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power windows27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back door30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft deterrent system32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank cap34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric moon roof36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1- 2

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TESTING THE SYSTEM
1. Open all the windows.
2. Set the system as described above.
The side doors and back door should
be locked with the key or wireless re-
mote control transmitter. Be sure to
wait until the indicator light starts flash-
ing.
3. Unlock any door from the inside. The
system should activate the alarm.
4. Stop the alarm as described above.
5. Repeat this operation for the other
doors and hood. When testing the
hood, also check that the system is
activated when the battery terminal is
disconnected and then reconnected.
If the system does not work properly,
have it checked by your Toyota dealer.
This indicates that the fuel filler door
is on the left side of your vehicle.1. To open the fuel filler door, pull the
lever up.
When refueling, turn off the engine.
CAUTION

Do not smoke, cause sparks or al-
low open flames when refueling.
The fumes are flammable.

When opening the cap, do not re-
move the cap quickly. In hot weath-
er, fuel under pressure could cause
injury by spraying out of the filler
neck if the cap is suddenly re-
moved.
Fuel tank cap

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2. To remove the fuel tank cap, turn
the cap counterclockwise by 90 de-
grees (to the pressure point 1), and
then turn it an additional 30 degrees
(to point 2). Pause slightly before
removing it.
It is not unusual to hear a slight swoosh
when the cap is opened.3. The removed cap can be stored on
the back side of the fuel filler door.
Position the cap so that the hooks point
to the left and right, and set it in the
receptacle on the back side of the door.When installing the cap, turn the cap
clockwise until you hear a click. When
you hear the click, the cap is fully
closed.
If the cap is not installed securely, the
malfunction indicator lamp comes on.
Make sure the cap is tightened securely.
The indicator lamp goes off after driving
several times. If the indicator lamp does
not go off, contact your Toyota dealer as
soon as possible.
CAUTION

Make sure the cap is installed se-
curely to prevent fuel spillage in
the event of an accident.

Use only a genuine Toyota fuel tank
cap for replacement. It is designed
to regulate fuel tank pressure.
NOTICE
To prevent damage to the cap, apply
force only in the turning direction to
the cap. Do not pull or pry it.

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2. Control System
*SFI system
The SFI system monitors the engine condition through the signals input from each sensor (Input signals from (1) to (12)
etc.) to the engine control module. And the control signal is output to TERMINALS #10, #20, #30, #40, #50 and #60 of
the engine control module to operate the injector (Inject the fuel). The SFI system controls the fuel injection operation by
the engine control module in response to the driving conditions.
*ESA system
The ESA system monitors the engine condition through the signals input to the engine control module from each sensor
(Input signals from (1) to (12) etc.). The best ignition timing is decided according to this data and the memorized data in
the engine control module and the control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 and IGT6. This
signal controls the igniter to provide the best ignition timing for the driving conditions.
*ACIS
The ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened or closed
according to the driving conditions to control the intake manifold length in three stages, for increased engine output in all
ranges from low to high speeds, when idling.
3. Diagnosis System
With the diagnosis system, when there is a malfunction in the engine control module signal system, the malfunctioning
system is recorded in the memory. The malfunctioning system can be found by reading the code displayed by the
malfunction indicator lamp.
4. Fail-Safe System
When a malfunction has occurred in any system, if there is a possibility of engine trouble being caused by continued control
based on the signals from that system, the fail-safe system either controls the system by using data (Standard values)
recorded in the engine control module memory or else stops the engine.
CIRCUIT OPENING Relay
5-3 : Closed with the starter running
EFI Relay
5-3 : Closed with the ignition SW at ON or ST position
E5 (A), E6 (B), E7 (E), E8 (D), E9 (C) Engine Control Module
Voltage at engine control module wiring connector
BATT-E1 : Always 9.0-14.0 volts
VC-E2 : Always 4.5-5.5 volts (Ignition SW at ON position)
VG-E2G : 1.1-1.5 volts (Engine idling and A/C SW off)
THA-E2 : 0.5-3.4 volts (Engine idling and intake air temp. 20°C, 68°F)
THW-E2 : 0.2-1.0 volts (Engine idling and coolant temp. 80°C, 176°F)
IGF-E1 : 4.5-5.5 volts (Ignition SW at ON position)
Pulse generation (Engine idling)
SIL-E1 : Pulse generation (During transmission)
TACH-E1 : Pulse generation (Engine idling)
STA-E1 : 6.0 volts or more (Engine cranking)
FC-E1 : 9.0-14.0 volts (Ignition SW at ON position)
0-3.0 volts (Engine idling)
SPD-E1 : Pulse generation (Ignition SW on and rotate driving wheel slowly)
W-E1 : Below 3.0 volts (Ignition SW at ON position)
NSW-E1 : 9.0-14.0 volts (Ignition SW on and other shift position in P or N position)
0-3.0 volts (Ignition SW on and shift position in P or N position)
PRG-E01 : 9.0-14.0 volts (Ignition SW at ON position)
TC-E1 : 9.0-14.0 volts (Ignition SW at ON position)
STP-E1 : 7.5-14.0 volts (Ignition SW on and brake pedal depressed)
0-1.5 volts (Ignition SW on and brake pedal depressed)
PTNK-E1 : 3.0-3.6 volts (Ignition SW at ON position)
1.3-2.1 volts (Ignition SW on and apply vacuum 2.0 kpa)
OX1B, OX2B-E1 : Pulse generation (Maintain engine speed at 2500 rpm for two minutes after warming up)
KNK1, KNK2-E1 : Pulse generation (Engine idling)
IGT1, IGT2, IGT3, IGT4, IGT5, IGT6-E1 : Pulse generation (Engine idling)
#10, #20, #30, #40, #50, #60-E01 : 9.0-14.0 volts (ignition SW at ON position)
Pulse generation (Engine idling)
Service Hints